Methods and apparatus for a fastener head having a dual zone socket area and a mating driver bit

ABSTRACT

Methods and apparatus for a fastener head having a dual zone socket area and a mating driver bit according to aspects of the present technology include a fastener configured with driving surfaces adapted to provide enhanced engagement between each other during use. The fastener includes a recessed socket area with a sidewall that has an upper inwardly tapering section and a lower vertical section that extends to the bottom of the recessed socket area. The upper inwardly tapering section of the sidewall may also include an offset relative to the lower vertical section to create asymmetrical driving and removal surfaces. The technology also includes a corresponding mating driver bit configured with mating surfaces to the fastener to provide enhanced engagement between the fastener and mating driver bit. The technology also allows either the fastener or the driving bit to be used with preexisting fasteners and driver bits.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/181,537, filed on Nov. 6, 2018, and incorporates the disclosure ofthat application in its entirety by reference. To the extent that thepresent disclosure conflicts with any referenced application, however,the present disclosure is to be given priority.

BACKGROUND OF INVENTION

Presently fasteners are made with variously shaped recessed sockets andmatched driving tools such as the Phillips design, straight walledhexagon, and other multi-lobe geometries. The walls and faces of thedriver and recess typically are designed to fit closely with each otherto achieve as much face-to-face (mating) contact between the drivingmember and driven surfaces of the fastener as possible. To enableinsertion of the driver into the recess, however, there must be someclearance between the driver and the recessed socket area of thefastener. As a result, the area of contact is typically less than fullface-to-face contact between the driver and the recessed socket area ofthe fastener. Consequently, when torque is applied by the driver, theforces applied to the fastener head and driver are concentrated inlocalized stress regions. These localized stresses may lead todeformation to the driver or fastener, breakage of the driver, andpremature cam-out of the fastener.

Poor fit between the recessed socket area and the driver is also causedby anti-corrosive coatings applied that may not be factored into designtolerance specifications. These coatings are often paints, applied by a“dip spin” method, which are thicker than zinc plating. The coatingsshorten the depth the driver can extend into the recessed socket areawhich may cause premature cam-out due to a reduction in the surfacecontact that could be achieved absent a coating.

SUMMARY OF THE INVENTION

Methods and apparatus for a fastener head having a dual zone socket areaand a mating driver bit according to aspects of the present technologyinclude a fastener configured with driving surfaces adapted to provideenhanced engagement between each other during use. The fastener includesa recessed socket area with a sidewall that has an upper inwardlytapering section and a lower vertical section that extends to the bottomof the recessed socket area. The upper inwardly tapering section of thesidewall may also include an offset relative to the lower verticalsection to create asymmetrical driving and removal surfaces. Thetechnology also includes a corresponding mating driver bit configuredwith mating surfaces to the fastener to provide enhanced engagementbetween the fastener and mating driver bit. The technology also allowseither the fastener or the driving bit to be used with preexistingfasteners and driver bits.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description when considered in connection withthe following illustrative figures. In the following figures, likereference numbers refer to similar elements and steps throughout thefigures.

FIG. 1 representatively illustrates a top view of a fastener inaccordance with an exemplary embodiment of the present technology;

FIG. 2 representatively illustrates a first perspective view of thefastener and recessed socket area in accordance with an exemplaryembodiment of the present technology;

FIG. 3 representatively illustrates a second perspective view of thefastener and recessed socket area in accordance with an exemplaryembodiment of the present technology;

FIG. 4 representatively illustrates a top view of an alternativelyshaped socket area of a fastener having five recessed lobes inaccordance with an exemplary embodiment of the present technology;

FIG. 5 representatively illustrates a perspective view of the socketarea having five recessed lobes in accordance with an exemplaryembodiment of the present technology;

FIG. 6 representatively illustrates a top view of an offset lower wallsection of the fastener in accordance with an exemplary embodiment ofthe present technology;

FIG. 7 representatively illustrates a first perspective view of theoffset lower wall section of the fastener in accordance with anexemplary embodiment of the present technology;

FIG. 8 representatively illustrates a second perspective view of theoffset lower wall section of the fastener in accordance with anexemplary embodiment of the present technology;

FIG. 9 representatively illustrates a top view of an offset lower wallsection of a third fastener having four driving surfaces in accordancewith an exemplary embodiment of the present technology;

FIG. 10 representatively illustrates a top view of an offset lower wallsection of a fourth fastener having five driving surfaces in accordancewith an exemplary embodiment of the present technology;

FIG. 11 representatively illustrates a top view of an offset lower wallsection of a fifth fastener having a nonlinear sidewall with six drivingsurfaces in accordance with an exemplary embodiment of the presenttechnology;

FIG. 12 representatively illustrates a prior first perspective view ofthe fastener shown in FIG. 11;

FIG. 13 representatively illustrates a second perspective view of thefastener shown in FIG. 12;

FIG. 14A representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIGS. 1-3 in accordance with anexemplary embodiment of the present technology;

FIG. 14B representatively illustrates a side view of the driver bitshown in

FIG. 14A in accordance with an exemplary embodiment of the presenttechnology;

FIG. 15 representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIGS. 4 and 5 in accordance with anexemplary embodiment of the present technology;

FIG. 16A representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIGS. 6-8 in accordance with anexemplary embodiment of the present technology;

FIG. 16B representatively illustrates an end view of the driver bit ofFIG. 16A in accordance with an exemplary embodiment of the presenttechnology;

FIG. 17A representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIG. 9 in accordance with anexemplary embodiment of the present technology;

FIG. 17B representatively illustrates an end view of the driver bit ofFIG. 17A in accordance with an exemplary embodiment of the presenttechnology;

FIG. 18A representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIG. 10 in accordance with anexemplary embodiment of the present technology;

FIG. 18B representatively illustrates an end view of the driver bit ofFIG. 18A in accordance with an exemplary embodiment of the presenttechnology;

FIG. 19A representatively illustrates a perspective view of a driver bitcorresponding to the socket area of FIGS. 11-13 in accordance with anexemplary embodiment of the present technology; and

FIG. 19B representatively illustrates an end view of the driver bit ofFIG. 19A in accordance with an exemplary embodiment of the presenttechnology.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present technology may be described in terms of functional blockcomponents and various processing steps. Such functional blocks may berealized by any number of components configured to perform the specifiedfunctions and achieve the various results. For example, the presenttechnology may employ various types of materials, fastening devices,driver systems and the like, which may carry out a variety of functions.In addition, the present technology may be practiced in conjunction withany number of processes such as the manufacture of fasteners, mechanicalattachment, and torque transmitting systems, and the system described ismerely one exemplary application for the invention. Further, the presenttechnology may employ any number of conventional techniques formetalworking, component manufacturing, tooling fabrication, and/orforming surfaces.

Methods and apparatus for a fastener head having a dual zone socket areaaccording to various aspects of the present technology may operate inconjunction with any suitable torque delivery system. Variousrepresentative implementations of the present technology may also beapplied to any device capable of rotating fasteners, such as a driverbit, screwdriver, and the like.

Referring now to FIGS. 1-5, a fastener head 100 for a fastener such as ascrew or bolt may comprise a recessed socket area 101 formed by asidewall extending into the fastener head 100 and arranged around alongitudinal axis 110 of the fastener head 100. The sidewall maycomprise an upper edge 204 disposed along or proximate a top surface ofthe fastener head 100 and a lower edge 206 disposed at or proximate to alower most section of the recessed socket area 101. The sidewall may beconfigured in any suitable shape or dimension for receiving a driver bit1400 (see FIG. 14) and may include one or more surfaces adapted to allowfor the transfer of torque between the driver bit 1400 and the fastenerhead 100. The sidewall may comprise a plurality of torque surfaces uponwhich forces may be applied to turn the fastener head 100 in a clockwise(installation) direction or a counter-clockwise (removal) direction. Forexample, a driving surface 106 may comprise a first torque surface forreceiving a driving force from the driver bit 1400 when the fastener isbeing installed, or otherwise screwed into place, generally in aclockwise rotation. Similarly, a removal face 108 may comprise a secondtorque surface for receiving a removal force (e.g. counter-clockwiserotation) from the driver bit 1400.

The driving surface 106 provides a contact area for receiving an appliedtorque from the driver bit 1400. It is known that increasing a contactarea along the driving surface 106 allows an applied torque to be moreevenly distributed across the entire driving surface 106 and may allowfor increased torque values while also making the recessed socket area101 less susceptible to cam-out. The driving surface 106 may beconfigured to comprise any suitable shape or dimension. The drivingsurface 106 may comprise a substantially flat surface or the drivingsurface 106 may be formed by a curving surface. Similarly, the removalsurface 108 provides a second contact area for receiving an appliedtorque from the driver bit 1400. The removal surface 108 may beconfigured to comprise any suitable shape or dimension.

The position and location of the driving and removal surfaces 106, 108are determined, at least in part, by the shape the sidewall makes aroundthe longitudinal axis 110. For example, referring now to FIGS. 1-3 and6-10, for fasteners having a recessed socket area 101 with a sidewallarranged with straight wall segments 112 to form patterns such astriangles, squares, pentagons, hexagons, and the like, the driving andremoval surfaces 106, 108 are located on opposite sides of each wallsegment 112. Referring now to FIGS. 4, 5, and 11-13, for fastenershaving a recessed socket area 101 with a sidewall arranged in acurvilinear line to form patterns having multi-lobular driving surfacessuch as a 4 lobe Phillips, a 6 lobe Torx® design, or the like, thedriving and removal surfaces 106, 108 are located on opposite sides ofeach lobe 402. One of ordinary skill in the art will recognize thatthese concepts can be applied to recessed socket areas 101 having anynumber of lobes 402 or straight walled segments 112.

Referring now to FIGS. 1-5, the sidewall may also comprise an upper wallsection 102 and a lower wall section 104. The upper wall section 102tapers inwardly from the upper edge 204 towards the longitudinal axis110. The taper of the upper wall section 102 creates a reduction in across-sectional area of the recessed socket area 101 between the upperedge 204 and a transition line 202 between the upper and lower wallsections 102, 104.

The upper wall section 102 may comprise a taper of between about 1° (onedegree) and about 3.6° (three and three-fifths degrees) relative to thelongitudinal axis 110. For example, in one embodiment, the upper wallsection 102 may taper inwardly by an angle of approximately 1.5° (oneand one-half degrees). In an alternative embodiment, the upper wallsection 102 may taper inwardly by an angle of between 1.25° (one andone-quarter degrees) and 1.5° (one and one-half degrees).

The upper wall section 102 extends only partway down into the recessedsocket area 101. The depth that the upper wall section 102 extends intothe recessed socket area 101 may be determined according to any suitablecriteria such as a desired amount of contact area or a wedging affectbetween the fastener head 100 and an inserted driver bit. In oneembodiment, the upper wall section 102 may comprise a height of lessthan half of the total depth of the recessed socket area 101. Forexample, the upper wall section 102 comprises a height of aboutone-third the total depth of the recessed socket area 101. In analternative embodiment, the wall section 102 may comprise a heightbetween one-quarter and three-quarters the total depth of the recessedsocket area 101.

The lower wall section 104 forms a vertical surface that extends fromthe transition line 202 to the lower edge 206. The cross-sectional areaof the recessed socket area 101 remains constant along the entire heightof the lower wall section 104. For example, referring now to FIGS. 1-5,in one embodiment the surfaces of the upper and lower wall sections 102,104 may be aligned with each other such that the cross-sectional area ofthe recessed socket area 101 is the same at any point along the heightof the lower wall section 104. This uniformity in cross-sectional areamay allow for a prior art driver bit having completely vertical drivingand removal surfaces to fit within the recessed socket area 101.

Alternatively, and referring now to FIGS. 6-13, the cross-sectional areaof the recessed socket area 101 along the lower wall section 104 may notremain constant along the entire height of the lower wall section 104due to an offset between the lower wall section 104 and the upper wallsection 102. For example, the entire lower wall section 104 between thelower edge 206 and the transition line 202 may be rotated about thelongitudinal axis 110 relative to the upper edge 204. The resultingchange to the surfaces of the upper and lower wall sections 102, 104creates a region of varying surface taper in the upper wall section 102and a region of varying vertical height in the lower wall section 104.

Referring now to FIGS. 6-8, in one embodiment, the lower edge 206 of asidewall having six wall segments 112 may be rotated by between 1° and6° (one degree and six degrees) in a generally clockwise direction aboutthe longitudinal axis 110 relative to the upper edge 204. Unlike thenon-offset lower wall section 104 (see FIGS. 2 and 3) where each wallsegment 112 has a uniform and generally rectangular surface area, theoffset of the lower wall section 104 in this embodiment alters thesurfaces of both the upper and lower wall sections 102, 104 causing thetransition line 202 to be angled downward contrary to the horizontaltransition line 202 in the non-offset embodiment of FIGS. 1-3. Thesurfaces of the upper and lower wall section 102, 104 take on morecomplex shapes causing an alteration in the size and shape of both thetapering region of the upper wall section 102 and the vertical region ofthe lower wall section 104. With particular reference to the upper wallsection 102, the offset of the lower wall section 104 causes the surfaceof the tapering region to vary in height between the driving surface 106and the removal surface 108. Specifically, the a depth that the taperingregion of the upper wall section 102 extends downward into the recessedsocket area 101 is greater at the removal surface 108 than it is at thedriving surface 106. As a result, the upper wall section 102 extendsmore deeply into the recessed socket area 101 along the removal surface108 portion of the sidewall than along the driving surface 106 portionof the sidewall.

Similarly, the vertical surface of the lower wall section 104 is alteredsuch that a height of the vertical surface is greater along the drivingsurface 106 of the sidewall than it is along the removal surface 108.Because upper wall section 102 comprises less taper at the drivingsurface 106, a vertical, or substantially vertical, line of insertion702 is formed between the upper edge 204 and the lower edge 206. Thisnear vertical line of insertion 702 may create a larger contact areaalong the entire driving surface 106 for the driving force to act on ascompared the non-offset embodiment of FIGS. 1-3.

By maintaining the substantially vertical line of insertion 702 alongthe entire depth of the recessed socket area 101, there is an increasein surface contact between the driver bit and the sidewall of thefastener head 100 when the driver bit is applying a force to tighten thefastener. The increased surface contact spreads the applied loads over agreater area and may prevent and/or reduce the likelihood that thedriver bit will break during use or that the recessed socket area 101may be prematurely worn as a result of point loading.

The extent to which the line of insertion 702 along the driving surface106 of the lower wall section 104 is vertical along the entire depth ofthe recessed socket area 101 is determined based on the amount of offsetor rotation between the lower wall section 104 and the upper wallsection 102. An offset that results in the lower edge 206 of the drivingsurface 106 of the lower wall section 104 aligning completely with theupper edge 204 will result in a completely vertical line of insertion702. For example, in one embodiment for a hex shaped recessed socketarea 101, the rotation of the lower wall section 104 relative to theupper wall section 102 to generate a completely vertical line ofinsertion 702 may be about 6° (six degrees). Accordingly, an offset ofless than 6° (six degrees) results in a line of insertion 702 along thedriving surface 106 that is not completely vertical but ends at somepoint below the upper edge 204 at the transition line 202 and isreplaced by the tapering surface of the upper wall section 102.

Referring now to FIGS. 9 and 10, the varying vertical and taperingregions for other embodiments formed by straight walled segments 112 issubstantially the same as that described above for the embodiment havingsix equally sized straight walled segments 112. The amount of offsetrequired to obtain a completely vertical line of insertion 702 along thedriving surface 106, however, may vary according to the particulargeometry of the wall segments 112. For example, a fastener head 100comprising a sidewall having three or four equally sized straight walledsegments 112 may require a larger offset or rotation than a fastenerhead 100 having a sidewall comprising five or more equally sizedstraight walled segments 112.

A natural result of creating a larger vertical line of insertion 702along the driving surface 106 from the offset between the upper andlower wall sections 102, 104 is that the amount of contact between anindustry standard driver bit, such as a 2 mm hex key, and the recessedsocket area 101 along the removal surface 108 is reduced. Referringagain to FIGS. 1-3, in the non-offset embodiment, the vertical surfacealong both the driving and removal surfaces 106, 108 is the same. Thisresults in an identical amount of surface contact on the driving surface106 during installation as on the removal surface 108 during removal ofthe fastener.

Conversely, and referring again to FIGS. 6-8, the offset creates adiffering amount of surface contact between the driver bit and thedriving and removal surfaces 106,108. For example, if a hex key bitcommonly known in the art is inserted into the recessed socket area 101such that the driver bit extends into the lower wall section 104, when adriving (clockwise rotation) force is applied the driver bit willcontact the sidewall along the line of insertion 702. In the case of theembodiments shown in FIGS. 6-8, the surface contact between the driverbit and the fastener head 100 along the line of insertion 702 maycomprise the entire depth of the recessed socket area 101. If a removal(counter-clockwise) force is applied, the driver bit will contact thesidewall of the recessed socket area 101 along the removal face 108 anddue to the tapering region of the upper wall section 102, the surfacecontact between the driver bit and the fastener head 100 will only existin the portion of the lower wall section 104 that is below thetransition line 202. The implication of this configuration is that theremoval force is spread over a smaller area than that of the drivingforce. Since it generally takes less removal force to loosen thefastener than is required to drive the fastener, the potential forbreaking a prior art driver bit or causing premature wear/cam-out of therecessed socket area 101 is reduced.

With continued reference to FIGS. 6-10, if a driving bit having fullytapering walls (non-vertical) as commonly known in the art is insertedinto the recessed socket area 101 then in addition to contact along theline of insertion 702, the contact area between the recessed socket area101 and the driving bit may be increased to include the tapering regionof the upper wall section 102. This increase in surface area contactwould provide an increase along the removal face 108 allowing thedriving and removal forces to be applied over a larger area.

Referring now to FIGS. 11-13, in an alternative embodiment having acurvilinear sidewall, the lower edge 206 of a sidewall having six lobes402 may be rotated by between 1° and 6° (one degree and six degrees) ina generally clockwise direction about the longitudinal axis 110 relativeto the upper edge 204. Unlike the non-offset lower wall section 104 (seeFIGS. 4 and 5) where each lobe 402 comprises a uniform tapering sectionand vertical section, the offset of the lower wall section 104 in thisembodiment alters the surfaces of both the upper and lower wall sections102, 104 resulting in a curvilinear transition line 1202. Withparticular reference to the upper wall section 102, the offset of thelower wall section 104 causes the surface area of the taper to varybetween the driving surface 106 and the removal surface 108 of each lobe402. Specifically, the surface area formed by the taper is greater onthe removal surface 108 side of each lobe 402 than it is on the drivingsurface 106 side of the same lobe 402. As described above, the taperedsurface of the upper wall section 102 extends more deeply into therecessed socket area 101 along the removal surface 108 of each lobe 402than along the driving surface 106 of each lobe 402.

Similarly, the vertical surface of the lower wall section 104 is alteredsuch that a height of the vertical surface is greater along the drivingsurface 106 of the sidewall than it is along the removal surface 108.Because upper wall section 102 comprises less taper at the drivingsurface, a vertical, or substantially vertical, line of insertion 702 isformed between the upper edge 204 and the lower edge 206. This nearvertical line of insertion may 702 create a larger contact area alongthe entire driving surface 106 for the driving force to act on ascompared the non-offset embodiment of FIGS. 4 and 5.

The extent to which the line of insertion 702 along the driving surface106 of each lobe 402 is vertical along the entire depth of the recessedsocket area 101 is determined based on the amount of offset or rotationbetween the lower wall section 104 and the upper wall section 102. Anoffset that results in the lower edge 206 of the driving surface 106 ofthe lower wall section 104 aligning completely with the upper edge 204will result in a completely vertical line of insertion 702. For example,in one embodiment, the rotation of the lower wall section 104 relativeto the upper wall section 102 to generate a completely vertical line ofinsertion 702 may be about 4° (four degrees). Accordingly, an offset ofless than 4° (four degrees) results in a line of insertion 702 along thedriving surface 106 that is not completely vertical but ends at somepoint below the upper edge 204 at the transition line 1202 and isreplaced by the tapering surface of the upper wall section 104.

As described above for the straight walled segment embodiment, theoffset creates a difference in the amount of surface contact between aninserted standard driver bit and the driving and removal surfaces 106,108. The concept is the same in the curvilinear sidewall embodiment,except that the driving and removal surfaces 106, 108 are disposed onopposing surfaces of each lobe 402 rather than along the same surface ofthe straight walled segment 112. In addition, the tapering portion ofthe removal surface 108 tends to create a wedge fit directing a drivingface of a typically tapered driver bit towards the line of insertion702.

Referring now to FIGS. 14A-15, the driver bit 1400 may comprise anysuitable device or system for mating with the fastener head 100 tofacilitate a transfer of torque from the driver bit 1400 to the fastenerhead 100. For example, the driver bit 1400 may comprise a sidewall orcurving multi-lobular surface configured to be selectively inserted intothe recessed socket area 101 of the fastener head 100 and at leastpartially conform to the recessed socket area 101. A fully conformingdriver bit 1400 comprising both a tapering section 1402 and a verticalwalled section 1404 may create sufficient surface contact with therecessed socket area 101 to couple the driver bit 1400 and the fastenerhead 100 together through a compressed, wedge, or “stick fit” such thatthe fastener head 100 does not fall off or otherwise automaticallydisengage from the driver bit 1400 after the driver bit 1400 has beeninserted into the recessed socket area 101. This design encourages thewedging effect towards the driving surface 106 along the taperingsection 1402.

In an alternative embodiment, the driver bit 1400 may comprise a longertapering section 1402 than that of the upper wall section 102 of therecessed socket area 101. By including a longer tapering section 1402,the vertical walled section 1404 of the driver bit 1400 may be able topenetrate further into the lower wall section 104 of the recessed socketarea 101 to provide greater surface contact across the lower wallsection 104 despite the presence of any coatings on the driver bit 1400or the fastener head 100. The tapering section 1402 of the driver bit1400 may comprise the same degree of taper (between 1° (one degree) and3.5° (three and one-half degrees)) towards a longitudinal axis 1410 ofthe driver bit 1400 as that of the upper wall section 102.

In addition, the vertical walled section 1404 may be sized such that itis slightly smaller than the size of a standard socket of a fastenerhead 100. In one embodiment, the vertical walled section 1404 of thedriver bit 1400 may be sized at about 97%-98% of an intendedcorresponding socket area. For example, if the driver bit 1400 isintended for use with a standard 2 mm hex socket, then the verticalwalled section 1404 may comprise an outermost radius of between 1.94 mmand 1.96 mm. The smaller size of the vertical walled section 1404accounts for the presence of any surface coatings that may be applied tothe recessed socket area 101 of the fastener head 100 and/or on thesurface of the driver bit 1400 itself.

In yet another embodiment, the driver bit 1400 may comprise only atapering section 1402. For example, rather than include a verticalwalled section 1404 configured to match that of the lower wall section104 of the fastener head 100, the driver bit 1400 may taper along theentire length of the sidewall or multi-lobular surface between a shankend and a bit end of the driver bit 1400. As described above, the end ofthe driver bit 1400 may be sized at about 97%-98% of an intendedcorresponding socket area to account for the presence of surfacecoatings.

Referring now to FIGS. 16A-18B, in yet another embodiment, the verticalwalled section 1404 may be offset from the tapering section 1402. Theoffset may be formed in a similar manner as described above with respectto the upper and lower wall sections 102, 104 of the recessed socketarea 101 except that the offset of the driver bit 1400 may be in theopposite direction when viewed from the end of the driver bit 1400. Thismay create a substantially fully conforming surface engagement betweenthe recessed socket area 101 and the sidewall of the driver bit 1400.More specifically, a surface height of the tapering section 1402,defined by a bit transition line 1412 disposed between the taperingsection 1402 and the vertical wall section 1404, is greater at theremoval surface 1408 than the surface height is at the driving surface1406. In other words, the tapering section 1402 extends further towardsthe end of the driver bit 1400 along the removal surface 1408 portiondriver bit 1400 than along the driving surface 1406.

Further, the vertical surface of the vertical walled section 1404 isaltered such that a height of the vertical surface is greater along thedriving surface 1406 of the sidewall than it is along the removalsurface 1408. Because the tapering section 1402 comprises less surfacearea along the driving surface 1406, a vertical, or substantiallyvertical, line of insertion may be formed between a shank end of thedriver bit 1400 and an end of the vertical walled section 1404 of thedriver bit 1400. This near vertical line of insertion may create alarger contact area along the entire driving surface 1406 for thedriving force to act on as compared the non-offset embodiment of FIGS.14A-15.

When embodiments of the driver bit 1400 shown in FIGS. 16A-18B are usedin conjunction with mating fastener heads 100 represented by FIGS. 6-10,the surface areas formed by the tapering and vertical portions act toenhance a “stick-fit” feature of the components. For example, referringnow to FIGS. 16A, 17A, and 18A, the tapering sections 1402 and thevertical wall sections 1404 of the driver bit 1400 each form triangularshaped surface areas. Similarly, the upper and lower wall sections 102,104 of the recessed socket area 101 also form triangular surface areas.The triangular surface areas may largely conform to each other to createtriangular intersections areas when the driver bit 1400 is inserted intothe recessed socket area 101. The triangular intersections areas providemuch greater surface contact between the driver bit 1400 and thefastener head 100 than can be achieved through other commonly usedmethods of creating a wedge or “stick-fit” that only fall along avertical or horizontal line of contact. The larger contact area allowsthe driver bit 1400 to hold the fastener straighter and with better gripthan existing wedge or “stick-fit” designs. Better grip between thedriver bit 1400 and the fastener head 100 provides increased benefitsfor machines such as robotic usage since the faster is held more tightlyand straighter after the driver bit 1400 is inserted into the recessedsocket area 101.

Referring now to FIGS. 19A and 19B, in an embodiment where the sidewallof the driver bit 1400 comprises a curvilinear sidewall forming amulti-lobular surface and the vertical walled section 1404 is offsetfrom the tapering section 1402, the surfaces of both the tapering andvertical walled sections 1402, 1404 form a curvilinear bit transitionline 1412. This causes the height of the tapered surface to differbetween the driving surface 1406 and the removal surface 1408 of eachlobe 402. As with the previous embodiment, the surface height formed bythe taper is greater on the removal surface 1408 of each lobe 402 thanit is on the driving surface 1406 of each lobe 402. As described above,the tapered surface of the tapering section 1402 extends further downthe length of the multi-lobular surface of the driver bit 1400 along theremoval surface 1408 of each lobe 402 than along the driving surface1406 of each lobe 402.

Similarly, the vertical surface of the vertical walled section 1404 isaltered such that the height of the vertical surface is greater alongthe driving surface 1406 of each lobe 402 than it is along the removalsurface 1408 of the lobe 402. Because the tapering section 1402comprises less taper along the driving surface 1406, a vertical, orsubstantially vertical, line of insertion may be formed between theshank end and the end of the driver bit 1400. This near vertical line ofinsertion may create a larger contact area along the entire drivingsurface 1406 for the driving force to act on as compared the non-offsetembodiment of FIG. 15.

The particular implementations shown and described are illustrative ofthe invention and its best mode and are not intended to otherwise limitthe scope of the present technology in any way. Indeed, for the sake ofbrevity, conventional manufacturing, connection, preparation, and otherfunctional aspects of the system may not be described in detail.Furthermore, the connecting lines shown in the various figures areintended to represent exemplary functional relationships and/or stepsbetween the various elements. Many alternative or additional functionalrelationships or physical connections may be present in a practicalsystem.

In the foregoing specification, the technology has been described withreference to specific exemplary embodiments. Various modifications andchanges may be made, however, without departing from the scope of thepresent technology as set forth in the claims. The specification andfigures are illustrative, rather than restrictive, and modifications areintended to be included within the scope of the present invention.Accordingly, the scope of the technology should be determined by theclaims and their legal equivalents rather than by merely the examplesdescribed.

For example, the steps recited in any method or process claims may beexecuted in any order and are not limited to the specific orderpresented in the claims unless specifically recited in the claims.Additionally, the components and/or elements recited in any apparatusclaims may be assembled or otherwise operationally configured in avariety of permutations and are accordingly not limited to the specificconfiguration recited in the claims. Benefits, other advantages andsolutions to problems have been described above with regard toparticular embodiments; however, any benefit, advantage, solution toproblem or any element that may cause any particular benefit, advantageor solution to occur or to become more pronounced are not to beconstrued as critical, required or essential features or components ofany or all the claims.

As used herein, the terms “comprise”, “comprises”, “comprising”,“having”, “including”, “includes” or any variation thereof, are intendedto reference a non-exclusive inclusion, such that a process, method,article, composition or apparatus that comprises a list of elements doesnot include only those elements recited, but may also include otherelements not expressly listed or inherent to such process, method,article, composition or apparatus. Other combinations and/ormodifications of the above-described structures, arrangements,applications, proportions, elements, materials or components used in thepractice of the present invention, in addition to those not specificallyrecited, may be varied or otherwise particularly adapted to specificenvironments, manufacturing specifications, design parameters or otheroperating requirements without departing from the general principles ofthe same.

1. A fastener having a head portion with a recessed socket areaextending into the head portion and a shank sharing a longitudinal axiswith the recessed socket area, comprising: a sidewall defining therecessed socket area having a top edge and a bottom edge; and aplurality of driving surfaces and removal surfaces disposed along thesidewall, wherein: an upper section of the sidewall tapers inwardlytowards the longitudinal axis between about one degree and about threeand three-fifths degrees from the top edge to a transition line; and alower section of the sidewall forms a vertical surface relative to thelongitudinal axis and is disposed between the transition line and thebottom edge, wherein: the lower section of the sidewall is offset in theclockwise direction from the upper section of the sidewall by a rotationof between one degree and six degrees; and a driving surface of thelower section of the sidewall at the bottom edge is aligned with adriving surface of the upper section of the sidewall to form a verticalline of insertion extending from the top edge to the bottom edge.
 2. Afastener according to claim 1, wherein a height of the upper sectioncomprises between one-third and two-thirds of a total depth of therecessed socket area.
 3. A fastener according to claim 1, wherein: across-sectional area of the recessed socket area decreases between thetop edge and the transition line; and a cross-sectional area of therecessed socket area remains constant between the transition line andthe bottom edge.
 4. A fastener according to claim 1, wherein: the topedge of the sidewall comprises at least four straight wall segments; andeach wall segment comprises a driving surface and a removal surface. 5.A fastener according to claim 4, wherein the top edge of the sidewallforms a hexagonal surface having six straight wall segments.
 6. Afastener according to claim 4, wherein the top edge of the sidewallforms a penta-head shaped surface having five straight wall segments. 7.A fastener according to claim 1, wherein: the transition line betweenthe upper section and the lower section is not perpendicular to thelongitudinal axis such that the transition line extends deeper into therecessed socket along each removal surface than along each drivingsurface; the upper section of the sidewall along each removal surfaceextends deeper into the recessed socket area and tapers inward a greaterdistance than the upper section of the sidewall along each drivingsurface; and the lower section of the sidewall along each drivingsurface extends higher up from the bottom edge of the recessed socketarea and remains vertical a greater distance than the lower section ofthe sidewall along each removal surface.
 8. A driver bit having alongitudinal axis, comprising: a sidewall extending between a shank endand a bit end; and a plurality of driving surfaces and removal surfacesdisposed along the sidewall, wherein: a tapering section of the sidewalltapers inwardly towards the longitudinal axis between about one degreeand about three and three-fifths degrees from the shank end to a bittransition line; and a vertical walled section of the sidewall forms avertical surface relative to the longitudinal axis and is disposedbetween the bit transition line and the bit end, wherein: the verticalwalled section of the sidewall is offset in the clockwise direction fromthe tapering section of the sidewall by a rotation of between one degreeand six degrees; and a driving surface of the vertical walled section ofthe sidewall at the bit end is aligned with a driving surface of thetapering section of the sidewall to form a vertical line of insertionextending from the shank end to the bit end.
 9. A driver bit accordingto claim 8, wherein: a cross-sectional area of the sidewall decreasesbetween the shank end and the bit transition line; and a cross-sectionalarea of the sidewall remains constant between the bit transition lineand the bit end.
 10. A driver bit according to claim 8, wherein thecross-sectional area of the vertical walled section comprises a size ofabout 97%-98% that of a socket area of a corresponding fastener head.11. A fastener according to claim 8, wherein: the top edge of thesidewall comprises at least four straight wall segments; and each wallsegment comprises a driving surface and a removal surface.
 12. Afastener according to claim 11, wherein the top edge of the sidewallforms a hexagonal surface having six straight wall segments.
 13. Afastener according to claim 11, wherein the top edge of the sidewallforms a penta-head shaped surface having five straight wall segments.14. A driver bit according to claim 8, wherein: The bit transition linebetween the tapering section and the vertical walled section is notperpendicular to the longitudinal axis such that the bit transition lineextends closer to the bit end along each removal surface than along eachdriving surface; the tapering section along each removal surface extendscloser to the bit end and tapers inward a greater distance than thetapering section along each driving surface; and the vertical walledsection along each driving surface extends closer to the shank end andremains vertical a greater distance than the straight walled sectionalong each removal surface.